GT ME 4793 - Glass Mat Reinforced Recycled Thermoplastics

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Outline Glass Mat Reinforced Recycled Thermoplastics ver 1 Motivation Recycling issues Why reinforce GMRT properties Commercialization Applications 1 ENG 4793 Composite Materials and Processes Motivation ENG 4793 Composite Materials and Processes 2 Mixed Thermoplastics have Poor Properties Large quantities of textile and carpet waste 2 Billion kg per year Mostly incompatible Manufacturing waste significant in Georgia True for nylon PP and PET Primary changes 50 Million kg per year Most is landfilled Most is carpet High concentration of nylon PP and PET Tensile strength Elongation Impact strength Therefore separate Need to recycle 3 ENG 4793 Composite Materials and Processes Hard to Separate Mixed waste fiber Chop Grind Extrude Dry ENG 4793 Composite Materials and Processes 4 Compatibilization Expensive Density Separator Mixed fiber waste Chop Grind Additives Filler e g block copolymer cost 4 kg often 10 wt PET Pelletize Filter Waste Compatibilizer Nylon Depolymerize Gray PP Pellets Injection Molding Extrusion Compounding Pelletizer Molding Pellets often low modulus ENG 4793 Composite Materials and Processes 5 ENG 4793 Composite Materials and Processes 6 1 Why Reinforce Why Glass Mat Fibers dominate properties 99 GPa Thermoplastic Glass Fiber Composite 60 vol undirectional Tensile Strength Modulus 0 05 3 5 2 2 70 40 Avoid fiber breakage Extrusion Compounding Fibers in 3 mm or greater Fibers out 1 mm or less typical Increase Impact Strength 5 Impact Strength 1 Fiber length mm ENG 4793 Composite Materials and Processes 7 1 3 10 100 8 ENG 4793 Composite Materials and Processes Conventional GMT Process Why Glass Mat Extruder Mixed Fiber Waste Chop Carding Glass Fiber Roving Chop Mat Laydown Cutter Heating Cooling Heating Double Belt Press Glass mat coils GMT Web Laminate Features Low viscosity resin Thick sheet 3 7 mm Slow Combine Filler Tolerant Process ENG 4793 Composite Materials and Processes 9 Paper Laying Process Glass Fibers Polymer powder Double belt press Wet Blend High capital costs Established commercially 10 ENG 4793 Composite Materials and Processes Materials Edge Trim Shear Lint Separated PP Source Carpet Manufacturing 40 Carpet Manufacturing 98 Old carpet SBR Nylon Filler 25 Sizing Dirt 1 Nylon 250 200 200 PP wt Air dryer GMT Web Other Fiber length mm Bulk Density 3 kg m Energy Intensive Drying Established commercially Good quality ENG 4793 Composite Materials and Processes GMT Original Recycled Materials Water and Surfactant Features Any viscosity resin Thin sheets Fast High capital costs Cooling 11 ENG 4793 Composite Materials and Processes 98 1 12 2 Original Recycled Materials Unreinforced Properties Property Materials Separated Typical virgin PP PP Edge trim Tensile strength MPa ksi Tensile modulus GPa ksi Elongation at break Izod impact strength J m ft lb in 17 9 2 6 30 4 4 4 29 0 38 6 4 2 5 6 1 43 207 1 51 219 1 04 1 73 150 250 9 32 200 500 16 0 3 27 0 5 21 32 0 4 0 6 13 ENG 4793 Composite Materials and Processes 14 ENG 4793 Composite Materials and Processes GMRT Properties Tensile Properties GMT samples Properties GMT samples Properties Density 3 g cm GMT Edge trim GMT Shear lint GMT Separated PP Molded Azdel 1 52 1 12 1 18 1 17 ASTM D 792 Tensile Strength MPa ksi Tensile Modulus GPa Msi GMT Edge trim GMT Shear lint GMT Separated PP Molded Azdel 109 15 8 84 1 12 2 87 12 7 78 0 11 3 5 72 0 83 5 86 0 86 6 83 0 99 5 67 0 82 ASTM D 638 15 ENG 4793 Composite Materials and Processes 16 ENG 4793 Composite Materials and Processes Dynatup impact testing Flexural Properties GMT samples Properties Properties GMT Edge trim Flexural Modulus GPa Msi Flexural Strength MPa ksi GMT Shear lint GMT Separated PP GMT Edge trim GMT Shear lint GMT Separated PP Molded Azdel Maximum load kN lb 3 23 725 3 71 835 3 31 745 3 48 783 Deflection at max load mm in Total energy absorbed J ft lb Sample thickness mm in 7 1 0 28 21 4 15 8 3 0 0 12 8 6 0 34 21 7 16 0 3 7 0 145 6 7 0 27 28 3 20 9 4 0 0 158 8 6 0 34 22 4 16 5 3 6 0 14 Molded Azdel 3 80 0 55 3 08 0 45 3 42 0 49 3 38 0 49 56 6 8 2 53 1 7 7 64 2 9 3 110 4 16 0 ASTM D 3763 impact velocity 3 4 m s ASTM D 790 ENG 4793 Composite Materials and Processes 17 ENG 4793 Composite Materials and Processes 18 3 Dynatup Impact Tester Commercialization Sequence 15 9 kg Dynatup tower Computer acquisition system 10 cm 10 cm sample Sample holder ENG 4793 Composite Materials and Processes Economic Analysis Patent Application Development Grant Process demonstration Property improvements Market assessment Business Plan 19 ENG 4793 Composite Materials and Processes Economic Analysis Georgia Development Grant Compare with commercial GMT Astechnologies Inc approached Assume equivalent processes Raw material costs per kilogram Virgin PP 0 70 Recycled PP 0 35 Glass Roving 1 80 Raw material cost savings per kilogram of GMRT 20 Glass 0 28 40 Glass 0 21 Manufactures laminating equipment Produces laminated products Located in Georgia Primary markets automotive and textiles Astechnologies acquires technology Demonstrated continuous processing Improved GMRT flexural strength Established market potential GMT sells for 3 30 per kilogram ENG 4793 Composite Materials and Processes 21 ENG 4793 Composite Materials and Processes Current volume 100 million kg yr Automotive industry dominates Appeal Due to poor interfacial adhesion incorporated maleated polypropylene CH 3 O 2 C C H2 CH C C C H3 CH 3 CH 3 H CH C H2 CH C H2 22 Market Improved Flex Strength CH 2 20 Low cost Rigidity Chemical resistance CH O Low density High impact strength Recycling Applications Found an optimum matched commercial GMT fracture mode changes to primarily tensile ENG 4793 Composite Materials and Processes 23 Battery trays Bumper beams Seats Dash board Guard rails Pump housings Containers Form boards for concrete Floating docks with foam core ENG 4793 Composite Materials and Processes 24 4 Concluding Remarks Georgia Composites Formed Thermoplastics can be recycled effectively as GMT composites Astechnologies majority owner EAC an affiliate Properties match virgin GMT Cost is less than virgin GMT Initial focus The breadth of this technology isn t known GMRT web Recycled PP Automotive applications How dirty can it be What mixtures should be avoided The science for this approach to recycling isn t known New production line started 1999 First commercial applications qualified in 1999 How do you predict properties for reinforced mixtures How important is long fiber length What additives are necessary ENG


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GT ME 4793 - Glass Mat Reinforced Recycled Thermoplastics

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